Method of making a coated abrasive article and coated abrasive article

Abstract

A method of making a coated abrasive article includes disposing a precursor make layer on a major surface of the backing, optionally partially curing the precursor make layer to provide a partially cured precursor make layer, disposing abrasive particles; partially embedding abrasive particles in the optionally partially cured precursor make layer; and further curing the optionally partially cured precursor make layer to form a make layer. The precursor make layer comprises components comprising: a) 50 to 97.99 percent by weight of phenol-formaldehyde resin; b) 1 to 49 percent by weight of resorcinol-formaldehyde resin; c) 1 to 49 percent by weight of at least one compound having at least one free-radically polymerizable group; and d) 0.01 to 1 percent by weight of a free-radical initiator. A size layer and/or supersize layer may be disposed over the make layer and abrasive articles. Coated abrasive articles made by the method are also disclosed.

1 . A method of making a coated abrasive article comprising:
 providing a backing having first and second opposed major surfaces   disposing a precursor make layer on the first major surface of the backing, wherein the precursor make layer comprises an at least partially cured reaction product of components comprising:
 a) 50 to 97.99 percent by weight of phenol-formaldehyde resin 
 b) 1 to 49 percent by weight of resorcinol-formaldehyde resin, 
 c) 1 to 49 percent by weight of at least one compound having at least one free-radically polymerizable group; 
 d) 0.01 to 1 percent by weight of a free-radical initiator; and 
 e) optional filler, 
 wherein the percent by weight of the components a) to d) is based on the combined weight of the components a) to d); and 
   optionally partially curing the precursor make layer to provide a partially cured precursor make layer; and   partially embedding abrasive particles in the optionally partially cured precursor make layer; and further curing the optionally partially cured precursor make layer to provide a further cured precursor make layer.   
     
     
         2 . The method of  claim 1 , wherein the components comprise:
 a) 50 to 89.99 percent by weight of the phenol-formaldehyde resin   b) 5 to 25 percent by weight of the resorcinol-formaldehyde resin,   c) 5 to 30 percent by weight of the at least one compound having at least one free-radically polymerizable group; and   d) 0.01 to 1 percent by weight of a free-radical initiator; and   e) optional filler,   wherein the percent by weight of the components a) to d) is based on the combined weight of the components a) to d).   
     
     
         3 . The method of  claim 1 , wherein the free-radical initiator comprises a free-radical photoinitiator. 
     
     
         4 . The method of  claim 1 , wherein the filler is present. 
     
     
         5 . The method of  claim 1 , further comprising disposing a supersize layer on the further cured precursor make layer and the abrasive particles. 
     
     
         6 . The method of  claim 1 , further comprising:
 disposing precursor size layer on the further cured precursor make layer and the abrasive particles; and   at least partially curing the precursor size layer to provide an at least partially cured size layer.   
     
     
         7 . The method of  claim 6 , further comprising disposing a supersize layer on the at least partially cured size layer. 
     
     
         8 . A coated abrasive article made by the method of  claim 1 . 
     
     
         9 . A coated abrasive article made by the method of  claim 2 . 
     
     
         10 . A coated abrasive article made by the method of  claim 3 . 
     
     
         11 . A coated abrasive article made by the method of  claim 4 . 
     
     
         12 . A coated abrasive article made by the method of  claim 5 . 
     
     
         13 . A coated abrasive article made by the method of  claim 6 . 
     
     
         14 . A coated abrasive article made by the method of  claim 7 .